Vehicle seat assembly

ABSTRACT

A vehicle seat assembly having a spring support for a seat cushion that includes a plurality of sinuous spring members extending between a border wire and a vertically disposed diaphragm. The sinuous spring members are located in a horizontal plane and encapsulated within a slab of high density plastic foam material, the front end of which is integrally formed with a block of high density foam material. The block serves as a support for maintaining the spring assembly at a predetermined distance above the seat frame.

United States Patent Arida etal.

[151 3,656,807 Apr. 18, 1972 [54] VEHICLE SEAT ASSEMBLY [72] Inventors:Louis K. Arida, Detroit; Edmond R.

Gionet, Warren; Donald E. Gunlock, Birmingham, all of Mich.

[73] Assignee: General Motors Corporation, Detroit,

Mich.

[22] Filed: Oct. 16, 1970 [21] App1.No.: 81,277

[52] US. Cl. ..297/452, 297/454, 297/DlG. 1, 297/DIG. 2, 5/259, 5/353.2

[51] Int. Cl ..A47c 7/02, A47c 23/02, A47c 23/00 [58] Field of Search..297/452, 460, 226, 224, DIG. 1,

297/DIG. 2, 218; 5/259-260, 353.2

[56] References Cited UNITED STATES PATENTS 2,996,733 8/1961Heffelfinger ..297/DIG. 1

3,005,213 10/1961 Brown et al ..297/DlG, 1 3,142,515 7/1964 Wall et al..297/DlG. 1

FOREIGN PATENTS OR APPLICATIONS 933,892 8/1963 Great Britain ..297/DlG.1 974,039 1 l/ 1964 Great Britain ..297/DlG. 2

Primary Examiner-Paul R. Gilliam Attorney-J. L. Carpenter and E. J.Biskup [5 7] ABSTRACT A vehicle seat assembly having a spring supportfor a seat cushion that includes a plurality of sinuous spring membersextending between a border wire and a vertically disposed diaphragm. Thesinuous spring members are located in a horizontal plane andencapsulated within a slab of high density plastic foam material, thefront end of which is integrally formed with a block of high densityfoam material. The block serves as a support for maintaining the springassembly at a predetermined distance above the seat frame.

5 Claims, 4 Drawing Figures PATENTED APR 18 I972 VEHICLE SEAT ASSEMBLYThis invention concerns a seat assembly and more particularly animproved spring support assembly which can be used with seat structuresof the type found in automobiles.

More specifically, the seat assembly made according to the presentinvention is intended to provide improved seating comfort for the seatoccupant without requiring a large number of metallic spring members andincludes a frame comprising a pair of laterally spaced and substantiallyparallel side members, each of which has a front end and a rear end. Afront rail member connects the front ends of the side members and a rearrail member connects the rear ends so as to form a generally rectangularframe which is structurally rigid and serves as a base for a springsupport assembly and the usual seat cushion. The spring support assemblyincludes a generally U-shaped border wire having the front sectionthereof located above the front rail member and the side sectionsthereof extending rearwardly for connection with the lower end of avertically disposed diaphragm, the upper end of which is connected tothe rear rail member. A plurality of sinuous spring members areuniformly spaced along the length of the border wire with each springmember having the front end connected to the front section of the borderwire and the rear end connected to the diaphragm. The sinuous springmembers are located in a horizontal plane and are encapsulated in a slabof high density foam material, the front end of which is integrallyformed with a vertical support that is made of the same material andthat extends downwardly in a seating position with the front railmember. The arrangement is such that the usual seat cushion can beplaced on the slab of high density foam material with the rear end ofthe seat cushion located adjacent the diaphragm support.

One feature of this invention is that it provides an improved seatassembly having a unique spring assembly support for the seat cushion.Another feature of this invention is that it provides a spring assemblywhich combines sinuous springs with a vertically disposed diaphragm thatconsists of a sheet of elastomeric material that is substantially longerthan its width and has a pair of laterally spaced and parallel rodsembedded in the diaphragm along its longitudinal edges. A still furtherfeature of this invention is in the encapsulating of a plurality ofsinuous spring members within a slab of high density plastic foammaterial and having one end of the spring members connected to a borderwire, while the rear end is connected to a horizontally disposed rodwhich in turn is connected to a vertically disposed diaphragm. Yet afurther feature of this invention is in the use of a unique support clipwhich permits the diaphragm of a spring assembly to bequickly connectedto the frame of the seat assembly.

Other features and advantages of the present invention will be apparentfrom the following detailed description when taken with the drawing inwhich:

FIG. 1 is an isometric view showing a seat assembly made in accordancewith the invention;

FIG. 2 is an enlarged plan view showing a diaphragm incorporated withthe seat assembly of FIG. 1;

FIG. 3 is an enlarged sectional view taken on line 3-3 of FIG. 2; and

FIG. 4 is an isometric view of a clip formed as part of the seatassembly.

Referring to the drawing and particularly FIG. 1 thereof, a seatassembly made in accordance with the invention is shown comprising aseat support frame 12 that incorporates a spring support assembly 14which in turn serves to support the usual seat cushion 16 of anautomobile. More specifically, the support frame 12 includes a pair ofgenerally L-shaped side members, one of which only is shown andindicated by the reference numeral 18, and a rear rail member 20 whichinterconnects the rear ends of the side members. A panel 22 is rigidwith and extends forwardly from the rear rail member 20 and terminateswith an upstanding lip or front rail member 24 which interconnects thefront ends of the side members.

Located within and supported by the seat support frame 12 is the springsupport assembly 14 which comprises a U-shaped border wire 26 having alongitudinally extending front section 28 integrally fonned withrearwardly extending side sections, one of which is shown and identifiedby the reference numeral 30. A plurality of sinuous spring members 32have their front ends rigidly clipped to the front section 28 of theborder wire 26 and extend rearwardly for connection with a verticallydisposed diaphragm 34 located adjacent to the rear rail member 20. Asseen in FIGS. 2 and 3, the diaphragm 34 takes the form of an elongatedsheet of elastomeric material and has the upper and lower ends thereofrespectively formed with bead portions 36 and 38. A pair of elongatedsupport rods 40 and 42 are embedded within the bead portions 36 and 38respectively, and it will be noted that a plurality of identical cutouts44 are formed in the lower end of the diaphragm 34 so as to expose thesupport rod 42 at equally spacedpoints to permit the rear ends of thesinuous spring members 32' to be connected to the diaphragm 34.Similarly, the upper end of the diaphragm 34 is formed with identicalcutouts 46 exposing portions of the support rod 40 that are carried by aplurality of support clips 48 removably secured to the rear rail member20. Thus, as seen in FIG. 3, the diaphragm 34 is located in asubstantially vertical plane and together with the sinuous springmembers 32 serves as resilient support for the seat cushion 16.

In order to prevent lateral shifting of the sinuous spring members andto provide increased resiliency to the spring support assembly 14, theentire border wire 26 together with all of the sinuous spring members 32are encapsulated within a slab 50 of high density urethane foam. Inaddition, the front end of the slab 50 is integrally formed with avertically disposed block 52 of high density urethane foam which servesas a stanchion for the front end of the spring support 14. As seen inFIG. 1, the block 52 is of a uniform thickness approximating that of theslab 50 and has a plurality of reinforcing triangular portions 54integrally formed along the length of the slab 50 for added columnarstrength. The lower end of the block 52 is seated within a suitablechannel (not shown) formed with the front rail member 24.

As seen in FIGS. 2, 3 and 4, each support clip 48 comprises a pair oflaterally spaced legs 56 and 58 which are formed with book portions 60and 62, and are connected to a base section 63. Each hook portion 60 and62 has a curved outward surface 64 dimensioned so it can be insertedwithin a vertical extending rectangular slot 66 provided at spacedintervals in the rear rail member 20. Below each book portion, each legis formed with an inclined abutment surface 68 which is adapted toengage the rear rail member 20 and coact with the hook portion forsecuring the support clip 48 thereto. In this regard and as seen in FIG.3, it will be noted that the slot 66 should have a vertical dimensionwhich will permit the hook portion to pass therethrough with the basesection 63 located in a vertical plane. The support clip 48 is thenrotated clockwise so as to cause the upper end of the hook portion toengage the inner surface of the rear rail member 20 while the abutmentsurface 68 engages the outer surface of the rear rail member 20 andthereby permits the support clip 48 to be secured to the rail member. Itwill be noted also that once the support clip 48 assumes the position ofFIG. 3, the rod 40 of diaphragm 34 can be readily slipped over an car 70integrally formed with the base section 63 for holding the diaphragm inthe assembled position.

From the above, it should be quite apparent that the seat constructionmade according to the invention requires a minumum of metallic springmembers. Moreover, assembly of the various portions of the seatstructure into the seat support frame 12 can be accomplished quicklywithout requiring any special equipment or tooling and with a minimum ofmanual operations. Moreover, it will be noted that the diaphragm 34 canbe formed as a separate member and clipped to the rear ends of thesinuous spring members 32 and the border wire 26. Thereafter, thecomposite can be placed in a mold for forming the slab 50 whichencapsulates the border wire 26 and the sinuous spring members 32. Thesupport block 52 can be formed at the same time so that the entirespring support 14 can be placed as a unit within the seat frame 12 withthe support block 52 seated within the front rail member 24 and the rod40 positioned within the support clips 48 as described above.

Various changes and modifications can be made in this constructionwithout departing from the spirit of the invention. Such changes andmodifications are contemplated by the inventors and they do not wish tobe limited except by the scope of the appended claims.

We claim:

1. A seat assembly including a seat cushion and a seat support frame,said seat support frame comprising a pair of laterally spaced andsubstantially parallel side members each of which has a front end and arear end, a front rail member connecting the front ends of said sidemembers, a rear rail member connecting the rear ends of said sidemembers so as to form a generally rectangular structure with said frontrail member, a spring support assembly for said seat cushion, saidspring support assembly comprising a generally U-shaped border wirehaving a front section located above said front rail member and a pairof integral side sections, a slab of high density plastic foam materialserving as a base for said seat cushion, a plurality of sinuous springmembers connected at one end to said front section and encapsulatedtogether with the border wire in said slab of high density plastic foammaterial, a diaphragm of elastomeric material connecting the sidesections of said border wire and the other ends of said sinuous springmembers to the rear rail member, and a block of high density plasticfoam material integrally formed with said slab adjacent said frontsection of the border wire and serving as a support for maintaining thefront portion of the spring support assembly above said front railmember at a predetermined distance.

2. The seat assembly of claim 1 wherein said diaphragm is formed with apair of parallel rods one of which is secured to said other ends of thesinuous spring members and the other of which is fixed to the rear railmember.

3. The seat assembly of claim 2 wherein a plurality of support clips arefastened to the rear rail member and serve to connect the other of saidrods to the rear rail member.

4. Theseat assembly of claim 3 wherein each of said support clipscomprises a base section formed with a pair of laterally spaced andparallel legs, each of said legs having a hook portion and an abutmentsurface, said rear rail member having vertically orientated slots formedtherein for accommodating the hook portions of said support clipswhereby each hook portion engages an inner surface of the rear railmember while said abutment surface engages an outer surface of said rearrail member for connecting the support clip to the rear rail member.

5. A seat assembly including a seat cushion and a seat support frame,said support frame comprising a pair of laterally spaced andsubstantially parallel side members each of which has a front end and arear end, a front rail member connecting the front ends of said sidemembers, a rear rail member connecting the rear ends of said sidemembers so as to form a generally rectangular structure with said rearrail member located at an elevation higher than the front rail member, aspring support assembly for said seat cushion, said spring supportassembly comprising a generally U-shaped border wire having a frontsection located above said front rail member and a pair of rearwardextending side sections located adjacent to and above said side members,a slab of high density plastic foam material serving as a base for saidseat cushion, a plurality of sinuous spring members located in asubstantially horizontal plane and connected at one end to said frontsection and encapsulated together with the border wire in said slab ofplastic foam material, an elongated diaphragm of elastomeric materiallocated in a substantially vertical plane for connecting the sidesections of said border wire and the other ends of said sinuous springmembers to the rear rail member, and a block of plastic foam materialintegrally formed with said slab ad acent said front section of theborder wire and serving as a support for maintaining the front portionof the spring support assembly above said front rail member at apredetermined distance.

1. A seat assembly including a seat cushion and a seat support frame,said seat support frame comprising a pair of laterally spaced andsubstantially parallel side members each of which has a front end and arear end, a front rail member connecting the front ends of said sidemembers, a rear rail member connecting the rear ends of said sidemembers so as to form a generally rectangular structure with said frontrail member, a spring support assembly for said seat cushion, saidspring support assembly comprising a generally U-shaped border wirehaving a front section located above said front rail member and a pairof integral side sections, a slab of high density plastic foam materialserving as a base for said seat cushion, a plurality of sinuous springmembers connected at one end to said front section and encapsulatedtogether with the border wire in said slab of high density plastic foammaterial, a diaphragm of elastomeric material connecting the sidesections of said border wire and the other ends of said sinuous springmembers to the rear rail member, and a block of high density plasticfoam material integrally formed with said slab adjacent said frontsection of the border wire and serving as a support for maintaining thefront portion of the spring support assembly above said front railmember at a predetermined distance.
 2. The seat assembly of claim 1wherein said diaphragm is formed with a pair of parallel rods one ofwhich is secured to said other ends of the sinuous spring members andthe other of which is fixed to the rear rail member.
 3. The seatassembly of claim 2 wherein a plurality of support clips are fastened tothe rear rail member and serve to cOnnect the other of said rods to therear rail member.
 4. The seat assembly of claim 3 wherein each of saidsupport clips comprises a base section formed with a pair of laterallyspaced and parallel legs, each of said legs having a hook portion and anabutment surface, said rear rail member having vertically orientatedslots formed therein for accommodating the hook portions of said supportclips whereby each hook portion engages an inner surface of the rearrail member while said abutment surface engages an outer surface of saidrear rail member for connecting the support clip to the rear railmember.
 5. A seat assembly including a seat cushion and a seat supportframe, said support frame comprising a pair of laterally spaced andsubstantially parallel side members each of which has a front end and arear end, a front rail member connecting the front ends of said sidemembers, a rear rail member connecting the rear ends of said sidemembers so as to form a generally rectangular structure with said rearrail member located at an elevation higher than the front rail member, aspring support assembly for said seat cushion, said spring supportassembly comprising a generally U-shaped border wire having a frontsection located above said front rail member and a pair of rearwardextending side sections located adjacent to and above said side members,a slab of high density plastic foam material serving as a base for saidseat cushion, a plurality of sinuous spring members located in asubstantially horizontal plane and connected at one end to said frontsection and encapsulated together with the border wire in said slab ofplastic foam material, an elongated diaphragm of elastomeric materiallocated in a substantially vertical plane for connecting the sidesections of said border wire and the other ends of said sinuous springmembers to the rear rail member, and a block of plastic foam materialintegrally formed with said slab adjacent said front section of theborder wire and serving as a support for maintaining the front portionof the spring support assembly above said front rail member at apredetermined distance.